In order to stay competitive, there has always been a strong focus on production control and optimization at Orkla.
On this basis, there was in 2008 initiated a process to analyze the production processes, both technically and with respect to the workflows, to lay the grounds for how a process-near IT system should be implemented to achieve optimal utilization of the production assets. The conclusion from this study was that there was a substantial potential for improvements by introducing such production support solutions.
Firstly it was decided to implement a complete data logging system where all process and production data were connected and logged via a common data hub. This was essential to transfer from local machine control to a central control and reporting system where all production assets were made available from one system.
It is essential for us to have control of all our production assets to stay competitive. This is especially valid for our raw material consumption and availability of the production equipment.
Per Erik Knivsflå, Production Manager at the Stranda site.
Prediktor with the APIS-platform was chosen as provider of the MES (Manufacturing Execution System) solution which now is in operation at the Stranda production sites. Initially, 4 functional areas were selected: SCADA, OEE (Overall Equipment Effectiveness), production reporting and production dispatching & execution. For the first capability, a graphical representation of the production lines was implemented in order to visualize the status of the machines along with critical production parameters. Further, these HMI screens were fitted with the capabilities to allow for central control of the assets. To monitor the asset utilization and to be able to analyze the major production losses, OEE capabilities were implemented. In contrast to many similar systems implemented in the industry which rely on manual data entries, this system is based on actual, real time, data automatically logged from © Prediktor AS 2017 the production lines.
“To be able to implement the appropriate corrective actions, it is essential to have correct underlying data. OEE-solutions based upon manually logged data will always be dependent on how exact the operators define e.g. down-times and stop reasons. Our experience is the this causes insecurity on the information that is provided and, thus, how appropriate the associated corrective actions are. In the APIS-system, data is based upon actual machine data and, thus”, the “truth” says Erling Fledsberg, Product Manager in Prediktor.
The OEE numbers are updated in real time and are visible both for the operators and production management. The production planning is done in SAP while the dispatching and execution of a production order is done in the APIS-system. In the project, a big focus has been put on the integration with SAP; master data such as articles, recipes, production orders etc. is transferred to APIS MES which then ensures dispatching at the correct production line, registration of inbound raw materials, and trace these through the production to finished goods.
Production batches along with consumption of raw materials is then reported back to SAP upon completion of a production order. This set-up also enables reporting of raw material consumption versus the defined recipes in real time. This means that the production organization immediately are able to identify possible deviations between estimated and actual consumption numbers and further is empowered to make appropriate actions.